Cerebral vasculature device

ABSTRACT

Novel cerebral vasculature devices are disclosed, including thrombectomy removal devices that include a continuous braided structure, a proximal portion, a distal portion, and a first expandable portion located between the proximal portion and the distal portion. The braided structure includes a plurality of wires. The proximal portion and the distal portion include polymer imbedded at least partially into the braided structure. The device is useful for removing thrombus from a patient&#39;s vasculature.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to devices useful for removing objectssuch as thrombus/or other foreign bodies from a patient's vasculature.More particularly, the invention relates to devices useful for removingthrombus from a patient's cerebral vasculature.

2. Description of Related Art

The use of a mechanical means to restore patency to obstructed vesselsis well known. These devices fit into many categories ranging fromhydraulic removal of thrombus, rotating cutting blades for calcifiedplaque, inflatable means for crushing or dragging thrombus, or amultiplicity of metal structures that either self-expand or can beexpanded to dredge a vessel or remove a stone.

Examples of these devices date back to the ‘Fogarty Catheter’ describedby Fogarty in U.S. Pat. Nos. 3,367,101; 3,435,826; and 4,403,612describing in detail improvements to a balloon catheter for embolectomypurposes. While suitable for many applications, dragging a balloonthrough the delicate, tortuous cerebral vasculature is not recommended.Crossing profiles of current state of the art balloon catheters wouldalso limit their use with typical neurovascular accessories (e.g.,microcatheters).

Mechanically expanded devices are also well known in the area ofobstruction removal. Clark specifically focused on the use of anexpanding braid for thrombus removal in U.S. Pat. No. 3,996,938. Histeaching utilized a braid that would expand under the force ofcompression delivered by an inner core wire affixed to the distal end ofthe braid.

Many refinements on this theme have occurred in the areas of stoneremoval, clot removal, foreign body removal, etc. All of these areassemblies of some nature which either self-expand or mechanicallyexpand under some delivered compressive load. Examples of these can beseen in Bates U.S. Pat. No. 6,800,080 in which parallel legs of thebasket allow bodies to enter the retrieval basket; Bates U.S. Pat. No.5,496,330 in which the basket is self-expanding and meant to collapseinto a provided sheath; Engelson U.S. Pat. No. 6,066,158 describing aself-expanding conical basket held collapsed in a ‘delivered’ statebecause of a ‘fixedly attached core wire’; and Samson U.S. Pat. No.6,066,149 describing an assembly consisting of a series of braidedexpanders.

These devices, while elegant, fail to address the major concern forapplications into the neurovasculature; namely, minimizing the crossingprofile (i.e., the cross-sectional area) of the devices. In general,these are all assembled devices consisting of many components that needto either be welded in place, or fixedly attached using collars, etc. Itis not seen how a device of these inventions would be compatible withphysician preferred microcatheters used to access the delicate, tortuousneurovasculature.

In many of the inventions, the issue of crossing profile has beencircumvented by describing fixed wire assemblies which are not meant topass through a microcatheter, rather, they are meant to navigate from alarge guiding catheter situated well proximal of the obstruction inlarge vasculature. Samson U.S. Pat. No. 6,066,149 is an example of thistype of assembly. As demonstrated in the figures, the device is anassembly in which the wire ends are managed into a collar. Theretractable core wire doubles as a conventional guidewire tip at itsdistal termination. This tip affords the steering of a guidewire and theability to puncture a clot to cross it, while the large body of thedevice encompasses the expander. Perhaps suitable for easily accessibleobstructions, this does not address the majority of anticipated cerebralvascular cases, or the physician preference, where amicrocatheter/guidewire combination is used to create a pathway acrossthe clot for angiographic visualization distal to the clot prior to theprocedure.

Wensel has anticipated the need for smaller devices to achieveneurovasculature compatibility in U.S. Pat. No. 5,895,398. In thispublication, he teaches the use of a helically shaped wire held straightfor delivery by the microcatheter. By using a single wire shaped into a‘cork-screw’ he has circumvented the complex assembly steps required inmuch of the other prior art resulting in large profiles. His invention,unfortunately, places the need of restraint on the microcatheter.Typically, physician preferred microcatheters are extremely flexible atthe distal end lending little ability to hold a shaped wire straight.This results in a trade-off of making the ‘cork-screw’ floppy (whichdegrades its ability to extract a clot), or making a custommicrocatheter which is stiff, limiting procedural access. Wensel'steaching also results in a structure which is not optimized forpreventing the distal migration of particulate during the removal ofclot due to the inherently large intertices of a device comprised ofonly a single, helically shaped wire.

SUMMARY OF THE INVENTION

The invention relates to cerebral vasculature devices and methods ofmaking the same. The cerebral vasculature device comprises:

Continuous braided structure comprising a plurality of wires, thebraided structure having a proximal portion, a distal portion, a firstexpandable portion between the proximal portion and the distal portion,and a lumen extending from the proximal portion to the distal portion;

The proximal portion and the distal portion each having an outerdiameter and an inner diameter and further including polymer imbedded atleast partially into the braided structure;

Core wire having a proximal end and a distal end, the core wire locatedwithin the lumen and extending from the braided structure proximalportion to a point at or distal to the braided structure distal portion;and

Atraumatic component attached to the core wire distal end and having anouter diameter at least equal to the inner diameter of the braidedstructure distal portion.

DESCRIPTION OF THE DRAWINGS

The operation of the present invention should become apparent from thefollowing description when considered in conjunction with theaccompanying drawings, in which:

FIG. 1 shows a representative cerebral vasculature device according toan aspect of the invention;

FIG. 2 shows a schematic cross-section of the device of FIG. 1;

FIG. 2A shows a variation of the device of FIG. 2;

FIG. 3 shows a representative cerebral vasculature distal subassemblydevice according to an aspect of the invention;

FIG. 4A shows the device of FIG. 3 and a catheter shaft according to anaspect of the invention;

FIG. 4B shows the device of FIG. 4A in its assembled form;

FIG. 5A shows in partial cross-section a further representative deviceaccording to an aspect of the invention;

FIG. 5B shows in partial cross-section the device of FIG. 5A with theexpandable portion in its expanded state;

FIG. 6 shows a further representative device according to a furtheraspect of the invention;

FIGS. 7A and 7B show a further embodiment according to an aspect of theinvention;

FIG. 8 shows a further embodiment according to an aspect of theinvention;

FIG. 9 is a longitudinal partial cross-section of a device according toan aspect of the invention;

FIG. 10 shows a device according to an aspect of the invention wherein afirst expandable portion is in its expanded state;

FIG. 11 shows a further embodiment of the device according to theinvention;

FIG. 12 shows the device of FIG. 11 wherein the first expandable portionis in its expanded state;

FIG. 13 shows a braided construction according to an aspect of theinvention;

FIG. 14 shows a braided construction according to an aspect of theinvention;

FIG. 15 shows a further representative device according to an aspect ofthe invention;

FIG. 16 shows a core wire according to an aspect of the invention;

FIG. 17 shows a core wire and atraumatic component assembly according toan aspect of the invention;

FIG. 18 shows an exploded view of a handle assembly according to anaspect of the invention;

FIG. 19 shows a cross-sectional exploded view of the handle assemblyshown in FIG. 18; and

FIG. 20 shows the handle assembly of FIG. 18, fully assembled.

DETAILED DESCRIPTION OF THE INVENTION

The cerebral vasculature device comprises:

Continuous braided structure comprising a plurality of wires, thebraided structure having a proximal portion, a distal portion, a firstexpandable portion between the proximal portion and the distal portion,and a lumen extending from the proximal portion to the distal portion;

The proximal portion and the distal portion each having an outerdiameter and an inner diameter and further including polymer imbedded atleast partially into the braided structure;

Core wire having a proximal end and a distal end, the core wire locatedwithin the lumen and extending from the braided structure proximalportion to a point at or distal to the braided structure distal portion;and

Atraumatic component attached to the core wire distal end and having anouter diameter at least equal to the inner diameter of the braidedstructure distal portion.

The invention is best understood with reference to the several figuresthat demonstrate certain exemplary, non-limiting, aspects of theinvention.

Referring to FIG. 1, there is shown a cerebral vasculature device 1,according to the present invention. As shown, cerebral vasculaturedevice 1 comprises a proximal portion 2, a first expandable portion 4, adistal portion 3, and atraumatic component 5. The device includes acontinuous braided structure having an outer diameter, an inner diameterand a lumen that extends from the proximal portion of the continuousbraided structure to the distal portion thereof. The proximal portion 2and the distal portion 3 further include polymer 6 imbedded at leastpartially into the braided structure (shown in FIG. 2). The device 1further includes core wire 12 having a proximal end and a distal end;the core wire is located within the lumen and extends from the braidedstructure proximal portion to a point distal to the distal most portionof the braided structure distal portion. The core wire 12 can be aground tapered stainless steel wire, but could also be any number ofmaterials including, but not limited to, nitinol wire, polymericfilament (including, but not limited to, expandedpolytetrafluoroethylene (“ePTFE”), polyester, Kevlar® fibers), tubularstructures, etc. The core wire 12 distal end extends through and isattached to atraumatic component 5, in this case a coil. Other suitablematerials can be used for atraumatic component 5, such as a polymerictubular structure. Atraumatic component 5 has an outer diameter at leastequal to the inner diameter of the braided structure distal portion 3.Also shown is tip 17 at the distal tip of core wire 12 and atraumaticcomponent 5.

FIG. 2 is a cross-section of the device depicted in FIG. 1 taken alongA-A, wherein polymer 6 is shown imbedding braided structure 8. Moreover,lumen 7 is shown being defined by the inner diameter of the braidedstructure 8 and polymer 6. Also shown is core wire 12, located in lumen7.

FIG. 2A shows an alternative to FIG. 2 wherein lumen 7 is defined by aninner polymer layer 6. Inner polymer layer 6 can be any suitable polymermaterial and can be provided as a coating, a thin tube, etc. In anaspect of the invention, inner polymer layer 6 comprises a lubriciouspolymer, such as polytetrafluoroethylene. In a further aspect of theinvention, inner polymer layer 6 is formed by the same polymer used toimbed the braided structure. Inner polymer layer 6 can extend anydesired length of the device. In an aspect of the invention innerpolymer layer 6 extends from the proximal portion 2 to the distal mostportion of distal portion 3.

The proximal portion 2 of the device in FIG. 1 can serve as the entirecatheter shaft of the device. In a further aspect of the invention, thecatheter shaft of the device may comprise a material different from thepolymer imbedded braided structure. In this regard, the continuousbraided structure can be part of a distal subassembly that may beattached to a suitable proximal catheter assembly.

Shown in FIG. 3 is a suitable distal subassembly according to an aspectof the present invention. The distal subassembly includes proximalportion 2 and distal portion 3, each comprising polymer imbedded atleast partially into the braided structure. The distal subassemblyfurther includes a first expandable portion 4 located between theproximal portion 2 and the distal portion 3. Further shown is atraumaticcomponent 5. Also shown are core wire 12 and tip 17, located at thedistal most portion of the device.

Turning now to FIG. 4A, shown is the above-described distal subassemblybefore being attached to catheter shaft 9. Catheter shaft 9 can compriseany suitable tubular structure, such as polymer imbedded braidedstructure, polymer tubing, metal tubing (such as hypo tube), etc. Thetubular structure can have a change in flexibility from a proximal pointto a distal point thereon. In an aspect of the invention, the distalpoint of the tubular structure can be more flexible than the proximalpoint. Catheter shaft 9 also includes a lumen which can extend over theentire length of catheter shaft 9. The lumen of catheter shaft 9 will bein communication with the lumen of the distal subassembly, once thecatheter shaft 9 and distal subassembly are attached together. Thecatheter shaft 9 and distal subassembly can be either permanently orremovably attached together. Any suitable means may be used to attachthe catheter shaft 9 and distal subassembly. In an aspect of theinvention, catheter shaft 9 and the distal subassembly are attached bybonding. The bond can be supplemented by, for example, crimping orshrink fitting a suitable tubular member over the bond region. Forexample, as shown in FIG. 4B, the bond region between shaft 9 andproximal portion 2 can be covered with a suitable metal tube, shown as14. The metal tube 14 can be compressed into the outer surfaces of eachof the shaft 9 and proximal portion 2 to provide a flush outer diametersurface of the device. The metal tube 14 can comprise any suitablemetal. In an aspect of the invention, the metal tube 14 comprisesradioopaque material. Also shown is polymer tube 15 located over metaltube 14 and the bond region. Polymer tube 15 can be any suitable polymermaterial. In an aspect of the invention, polymer tube 15 is a shrink-fitpolymer tube. The polymer tube 15 can provide further reinforcement tothe bond region.

In an aspect of the invention, the catheter shaft 9 is removablyattached to the distal subassembly. Therefore, the distal subassemblymay be used as an implantable device if desired. For example, it may bedesirable to leave in the body the device in its expanded state to actas an occlusive device, to treat aneurysms, to act as a filter, todilate a vessel, etc. In these instances, the distal subassembly can bemade in the same manner previously described; however, a suitablemechanism for removably attaching the subassembly to the catheter shaftcan be used. Any suitable means for removably attaching the distalsubassembly to the catheter shaft can be used including, but not limitedto, electrocorrosive means, mechanical means including friction fit,hook and loops, etc.

FIGS. 5A and 5B demonstrate one exemplary removable attachmentembodiment wherein core wire 12 extends in a proximal direction from apoint distal to the braided structure distal portion 3, through theexpandable portion 4, to a point proximal to proximal portion 2. At apoint proximal to the expandable portion 4, core wire 12 is in the formof a loop, or the core wire 12 can be attached to a loop-shaped wire.The loop is sized slightly larger than the inner diameter of theproximal portion 2 so that the proximal portion acts to constrain theloop, as shown in FIG. 5A. An actuation fiber 16 (or wire) is locatedthrough the loop on core wire 12. In an aspect of the invention, thefiber can be ePTFE fiber. Both ends of fiber 16 are pulled through theinner diameter of catheter shaft 9 through to the proximal end of thecatheter. The expandable portion 4 can be fully actuated by pulling in aproximal direction both ends of the fiber 16, thus pulling the loop inthe core wire to a location proximal of the proximal portion. Thisallows the loop in the core wire to spring open, thus maintainingexpandable portion 4 in its expanded configuration, as shown in FIG. 5B.One end of the fiber 16 is then pulled from the proximal end of thecatheter shaft allowing the distal subassembly to be freed from thecatheter shaft. This mechanism is also useful in instances where morethan one expandable section are present or when the porosity of theexpandable section is controlled via a film covering. For example, adetachable distal subassembly of particular interest may have twoexpandable sections in which one section is sized/shaped to fit insidethe neck of a cerebral aneurysm and the other section is sized to fit inthe parent vessel, thus interrupting flow into the aneurysm.

FIG. 6 demonstrates a still further aspect of the present inventionwherein the device includes a second expandable portion 10, locateddistal to the first expandable portion 4. Also shown is intermediateportion 11, which can comprise polymer imbedded at least partially intothe braided structure. Intermediate portion 11 could also be formed orrestrained from expansion via various other methods including, but notlimited to, a change in braid angle, a marker band, a polymeric filmcovering, or by heat setting, etc. The intermediate portion 11 can beany suitable length. When using the device to remove thrombus from thecerebral vasculature, the first expandable portion 4 can be advancedjust distal to the thrombus to be removed. Both expandable portions 4,10 can be expanded (i.e., by moving the core wire 12 proximally), andthe first expandable portion 4 can be used to pull the thrombus in aproximal direction, with the second expandable portion 10 serving as asafety feature to catch any debris that may break off from the thrombusand float in a distal direction. In an aspect of the invention, thisprocedure can be carried out under retrograde blood flow conditions tofurther limit the possibility of debris being carried in a distaldirection, toward more delicate vasculature. Moreover, first expandableportion 4 and/or second expandable portion 10 can be provided with anouter polymer cover (discussed in more detail below).

In an aspect of the invention (as mentioned above) the intermediateportion 11 can comprise a braided structure having a different braidangle from the braid of the proximal section 2 and the distal section 3.For example, shown in FIG. 7A is an alternative device according to anaspect of the invention. The device includes proximal portion 2,expandable portions 4 and 10, with intermediate portion 11 locatedbetween the expandable portions 4 and 10. The device further includescore wire 12, atraumatic component 5 and tip 17. By carefully selectingthe braid angle of intermediate portion 11, it is possible to restrainthis section from expanding (or limit the degree of expansion relativeto the expandable portions 4 and 10) without having to imbed theintermediate braid with polymer or otherwise provide a constrainingmeans. Shown in FIG. 7B is the device with the expandable portions 4 and10 in their expanded states. It should be understood that although thefigure shows intermediate portion 11 having the same outer diameter aswhen the expandable portions 4 and 10 were in their unexpanded states,it is possible to adjust the braid angle of intermediate portion 11 suchthat the portion expands in diameter any desired amount, thuscontrolling the distance between the expandable portions 4 and 10 whenexpanded.

In a further aspect of the invention, the distance between twoexpandable portions can be controlled by providing a second device witha lumen or hollow core wire to allow for an appropriately sized deviceaccording to the invention to be advanced through the lumen or hollowcore wire to a point distal to the second device. For example, as shownin FIG. 8, a first device comprises proximal portion 2, distal portion3, and expandable portion 4 located therebetween. The first devicefurther includes core wire 12, atraumatic component 5 and tip 17. Thefirst device is shown having been at least partially advanced throughthe lumen of a second device. The second device comprises proximalportion 2, distal portion 3, and expandable portion 4. The second devicealso comprises a lumen or hollow core wire (not shown) sized to allowthe first device to pass therethrough. The second device can include anysuitable means to cause expandable portion 4 to expand, and preferablyincludes an atraumatic component, such as discussed above. In an aspectof the invention, the second device also includes a core wire (i.e., ahollow core wire), an atraumatic component attached to the core wire,and may also include a tip, as discussed above. The tip will also behollow to allow for advancement of the first device therethrough.

Turning now to FIG. 9, there is shown a longitudinal schematic partialcross-section of a device according to an aspect of the invention. Shownin cross-section is proximal portion 2 comprising polymer 6 imbeddingthe braided structure 8. Also shown is first expandable portion 4 anddistal portion 3 comprising polymer imbedding the braided structure.Further shown is core wire 12, extending from the proximal end of thedevice, through the lumen, and being attached to atraumatic component 5.Atraumatic component 5 has an outer diameter just larger than the innerdiameter of distal portion 3. In an aspect of the invention core wire 12extends from the proximal end of the device, through the lumen, and isattached to the proximal end of atraumatic component 5.

FIG. 10 shows the device of FIG. 1, where the expandable portion 4 is inits fully expanded state. Expandable portion 4 can be expanded when corewire 12 is proximally retracted while the braided structure proximalsection is held fast. In an aspect of the invention, the expandableportion 4 is atraumatic to a patient's target vessel when it is in itsmaximum expanded state. Moreover, the maximum expanded diameter can beequal to or larger than the diameter of the patient's target vessel.

In a further aspect of the invention, the first expandable portion(and/or the second expandable portion) can be provided with an outerpolymer cover. Shown in FIG. 11 is an example of such a device. Thedevice is essentially the same as depicted in the figures discussedabove, with the addition of the polymer cover 30 surrounding andcompletely covering the expandable portion. FIG. 12 shows the device ofFIG. 11 wherein the expandable portion is in a partially expanded state.Any suitable polymer film, tape, etc. can be used to cover theexpandable portion in a radially distensible manner. For example,suitable polymers include polytetrafluoroethylene (e.g., ePTFE),polyurethane, silicone, polyester, polyethylene, and bioabsorbablepolymers. Polymer covering can be 100% occlusive in nature, or can haveany variation of porosity allowing for a controlled flow rate orparticle separation.

In an aspect of the invention, the polymer cover can comprise anysuitable number of layers of ePTFE film which can be fused together withheat, then wrapped around expandable portion 4 in such a manner that itsmicrostructure allows the expandable portion 4 to freely radiallyexpand. For example, ePTFE polymer covering can comprise interconnectednodes and fibrils, with the covering arranged such that the fibrils areoriented longitudinally when the covering is in its small diameterstate. Upon expansion to its larger diameter state, the fibrils canrotate and be oriented more circumferentially. Upon collapse, the endsof the covering can be pulled out as the expandable portion lengthens.This will act to realign the fibrils longitudinally. This same film canthen collapse when the expandable portion is allowed to collapseunderneath it. In an exemplary embodiment, 4 layers of ePTFE film can bestacked one on top of the other and wrapped around a 5 mm stainlesssteel mandrel in a “cigarette” wrap configuration, with the film beingoriented such that the majority of fibrils are perpendicular to the axisof the mandrel. Although any suitable ePTFE film can be useful, withvarious wrap orientations as well, particularly attractive is anembodiment that comprises 4 layers of ePTFE film having a density ofabout 0.3 g/cc, a 50 micron fibril length, and a film thickness of about0.03 mm. Once positioned on the mandrel, the film can be heated at about370° C. for about 25 minutes to fuse together the layers of film, thusforming a tubular wall on one layer. The tube can be cut to a length ofabout 4 inches and removed from the mandrel. A 0.012 inch mandrel canthen be positioned into the inside diameter of the tubular structure.The tubular structure can then be stretched/necked down to a point wherethe tubular structure's inner diameter is essentially equal to the outerdiameter of the mandrel. The tubular structure can be removed andpositioned over a suitable device according to the invention, with onlya slight interference fit. Two Pt/Ir marker bands can then be placedover the tubular structure at points located over the proximal portionand the distal portion. A radial crimper can be used to crush the Pt/Irbands down onto the proximal and distal portions of the device. Thecrimping step can be carried out under suitable heat to melt or softenthe polymer portion of the proximal and distal portions, thus allowingthe bands to be imbedded into the polymer to result in a flush outersurface of the device as well as to increase the strength of the bond.In an aspect of the invention, the polymer at the proximal and distalportions can comprise PEBAX® 7033 polymer and during the crimping stepheat can be applied at 250° F. for about 6 seconds under 40 psi of airpressure. A steel mandrel can be placed inside the lumen of the deviceduring the crimping step to prevent collapse of the device duringheating and crimping.

The polymer cover need not be bonded to the expandable section. However,as noted above, the polymer cover should be fixedly attached to theproximal and distal portions of the device, but should be free to moveover the expandable section. The polymer cover 30 can be secured toproximal portion 2 and distal portion 3 in any suitable manner. In anaspect of the invention, as shown in FIGS. 11 and 12, the polymer coveris secured to the proximal portion 2 and distal portion 3 using metaltubes 32 and 33, respectively. As mentioned above, the metal tubes 32and 33 can be compressed into the outer surfaces of each of the proximalportion 2 and distal portion 3 to provide flush outer surfaces on eachportion. The metal tubes 32 and 33 can comprise any suitable metal. Inan aspect of the invention, the metal tubes comprise radioopaque metal.

By providing the first and/or second expandable portion with a polymercover, the device may be particularly useful in disrupting flow to ananeurysm or across an arterial-venous malformation, or in preventing thedistal flow of debris in the case of loose emboli. In some instances,macroporosity may be desired to allow the flow of blood through thedevice while filtering out debris. In an aspect of the invention, a filmcovering having 100 micron pores placed with a laser and ananticoagulant coating could be used to prevent the flow of debris largerthan 100 microns. Devices embodying this aspect of the invention will beparticularly useful due to the small profiles afforded by this inventionallowing the devices to be delivered to the neurovasculature through amicrocatheter.

The braided structure of the device can comprise a plurality of wiresselected from, for example, the group consisting of round profiles, flatprofiles, and combinations thereof. In an aspect of the invention, amajority of the wires have a round profile. In a further aspect of theinvention, the majority of round wires have an outer diameter of about0.002 inch or less. In a still further aspect of the invention, thewires have an outer diameter of 0.0015 inch or less. In a still furtheraspect of the invention, the majority of wires have an outer diameter ofabout 0.001 inch or less.

The wires can comprise any suitable material. In an aspect of theinvention, the wires comprise metal. Particularly attractive wires cancomprise nitinol. In a further aspect of the invention, the wires cancomprise radioopaque material. In a still further aspect of theinvention, the radioopaque material can comprise a metal selected fromthe group consisting of platinum, iridium, gold and platinum/iridiumalloy.

The braided structure can comprise any number of wires. In an aspect ofthe invention, the braided structure comprises 32 wires or more. In afurther aspect of the invention, the braided structure comprises 48wires or more. In a still further aspect of the invention, the braidedstructure comprises 60 wires or more.

The braided structure can comprise wires oriented at any suitablebraiding angle. In an aspect of the invention, the braided structure ofthe first expandable portion comprises a plurality of wires oriented ata first angle, while at least a portion of the device comprises braidedstructure comprising wires oriented at a second angle different from thefirst angle. In a further aspect of the invention, the braided structureof the first expandable portion comprises wires oriented at an angle ofabout less than or equal to 10 degrees, as measured from thelongitudinal axis of the braided structure. In a still further aspect ofthe invention, the braided structure of the first expandable portioncomprises wires oriented at an angle of about less than or equal to 8degrees, as measured from the longitudinal axis. In a still furtheraspect of the invention, at least a portion of the proximal portion andthe distal portion comprise a plurality of wires oriented at the sameangle as that of the wires of the first expandable portion. In a furtheraspect of the invention, at least a portion of the proximal portioncomprises a plurality of wires oriented at an angle different from thefirst expandable portion. For example, shown in FIG. 13 is braidedstructure 4 comprising braided wires. At the proximal end P of thebraided structure, the wires are braided at a first relatively highangle, while the wires at the distal end D are braided at a second,relatively low angle, the braid angles being measured from thelongitudinal axis L of the braided structure. This aspect of theinvention may be particularly useful in that the higher angle braidedportion may find utility as a catheter shaft that is more kink resistantthan a shaft formed with a relatively lower braid angle. Moreover, thelower braid angle may be particularly useful as the expandable portion(lower braid angles may allow for proper expansion of the expandableportion when compared to higher braid angles).

It should be understood that a desired braid angle can be obtained usingreadily available braiding machines by setting the machine setting to adesired pics per inch (PPI) setting. The higher the PPI, the higher thebraid angle. Particularly attractive devices can have an inner diameterof about 0.01 inch and may comprise an expandable portion having a braidangle of about 7 degrees (i.e., about 26 PPI), and a proximal portionhaving a braid angle of about 21 degrees (i.e., about 80 PPI). Thus,using well known braiding machines, braided structures according to theinvention can be fabricated with any number of sections with varyingbraid angles. As mentioned, the braid angles are obtained by enteringsettings into the machine. Thus, use of such machines can result in“transition regions” being formed in the braided structure. As themachine setting changes from one setting to the next, the braid angleswill be somewhere between the two set angles in this transition region.

Such a transition region is shown, generally, as area 18 in FIG. 14.Several methods can be used to reduce the size of, eliminate, or coverover the transition region. For example, the size of the transitionregion can be reduced (and even eliminated) by stopping the braidingmachine, changing the braid angle setting while the braided structure isheld fast, and then restarting the machine. In an aspect of theinvention, the braid will change from a higher angle to a lower angle inless than a centimeter. In a still further aspect of the invention, thebraid will change from a higher angle to a lower angle in less than 5mm. In a still further aspect of the invention, the braid will changefrom a higher angle to a lower angle in less than 3 mm.

Moreover, the transition region could be covered or partially coveredwith, for example, a metal or polymer tube or scrimp to add, forexample, rigidity to the transition region. Furthermore, the braidedstructure with a transition region could first be at least partiallyimbedded with suitable polymer, and then a metal tube (preferably aradioopaque material) can be heated and compressed around the transitionregion of the braided structure to form a suitable device. If the metaltube comprises radioopaque material, the tube can serve as a marker bandto help the physician guide the device to a desired target region.

The above-described embodiment is shown, for example, in FIG. 15, wheremetal tube 14 has been located over a transition region located justproximal to expandable portion 4. As with the use of the metal tube tocover a bond region (discussed above), the metal tube 14 in thisembodiment may also be imbedded into the surface of proximal portion 2to be flush with the outer diameter of the proximal portion. Thus,providing a relatively smooth, continuous outer surface along the lengthof the device. Furthermore, the metal tube can comprise any suitablemetal. In an aspect of the invention the metal tube comprisesradioopaque material. Of course, an additional marker band can belocated distal to the expandable portion 4, if desired.

In an aspect of the invention, the transition region can be eliminatedby bonding together two or more sections of braided structure ofdiffering braid angles.

The polymer imbedded at least partially into the braided structure ofthe proximal portion, the distal portion, and, when used, theintermediate portion, can comprise any suitable polymer material. Forexample, the polymer may comprise a material selected from the groupconsisting of polyimide, PEBA, polyurethane, nylon, polyethylene, andsilicone. Moreover, the polymer can further comprise suitable fillermaterial. For example, a suitable polymer can comprise polyimidecontaining PTFE filler distributed throughout the polymer. In an aspectof the invention, the polymer substantially completely imbeds thebraided structure for essentially the entire length of the proximalportion, the distal portion, and, when used, the intermediate portion.Moreover, an outer polymer layer can be provided to provide the devicewith a polymer cap. The polymer cap will increase the outer diameter ofthe braided structure and can further modify the properties of thedevice. The polymer should be selected to provide the necessary rigidityto the device to allow the physician to advance the device and alsoprovide structural support to the device so that when the expandableportion is expanded (e.g., by pulling proximally on the proximal end ofthe core wire) the remainder of the device outer diameter remainssubstantially unchanged. Moreover, the polymer should also provide thenecessary flexibility to the device to allow the device to be advancedthrough the delicate cerebral vasculature. Furthermore, the compositionof the polymer can be varied along the length of the device to providefor varying flexibility along the length of the device.

In a further aspect of the invention, the polymer material may compriseradioopaque material. For example, the polymer may comprise a materialselected from the group consisting of barium sulfate, bismuth trioxide,etc.

In an aspect of the invention, the braided structure proximal portionand distal portion can have outer diameters of about 0.020 inch or less.In a further aspect of the invention, the braided structure proximalportion and distal portion can have outer diameters of about 0.017 inchor less.

In a further aspect of the invention, the braided structure can have aninner diameter of about 0.010 inch and an outer diameter of about 0.014inch. Moreover, in such an embodiment, the polymer can have an innerdiameter of about 0.010 inch and an outer diameter of about 0.016 inchwhen fully impregnating the braided structure, thus providing a 0.001inch polymer cap around the proximal portion and the distal portion ofthe braided structure. In a still further aspect, at least some of thepolymer can be impregnated to serve as an inner liner for the proximalportion and the distal portion. In such a case, the polymer can definean inner diameter of about 0.010 inch (with the braid having an innerdiameter of about 0.011 inch) and an outer diameter of about 0.015 inch.Moreover, the braided structure can have an outer diameter of about0.015 inch. Further, when the device proximal portion is attached to asuitable tubular structure (e.g., a catheter shaft), the tubularstructure can have essentially the same inner and outer dimensions asthe braided structure proximal and distal portions.

As stated, the device includes atraumatic component 5. The atraumaticcomponent can be in the form of polymer tubular structures, metal coils,etc. When the atraumatic component comprises metal coil, the metal maycomprise a material selected from the group consisting of, for example,platinum, platinum/iridium, stainless steel, and nitinol. In an aspectof the invention, the atraumatic component comprises radioopaqueplatinum/iridium alloy. While the atraumatic component should have anouter diameter larger than the inner diameter of the distal portion, itmay also further comprise a section of reduced outer diameter thatenters the lumen of the distal portion to aid in centering the core wirein the lumen of the braided structure. This section of the atraumaticcomponent could be a coil of tapering diameter or a second coil, etc.

The device further includes a core wire that may extend essentially theentire length of the device, wherein the distal end of the core wire isattached to the atraumatic component. The core wire can comprise, forexample, a material selected from the group consisting of stainlesssteel and nitinol or from a group of polymeric filaments includingePTFE, polyester, Kevlar® fibers, etc. or a multifiber composite. It canfurther comprise a tapering outer diameter, resulting in, for example,increasing flexibility of the device distally. The distal end of thecore wire may contain a section which has been rolled to a rectangularprofile allowing for shaping of the atraumatic tip by the physicianusing standard techniques. Moreover, the core wire can be a tubularstructure of any suitable material, such as a polymer tube or a metaltube or a film tube comprised of discrete layers of ePTFE film whichhave been fused together to form a tube. The tubular structure can besolid or hollow. When the tubular structure is hollow, the hollow tubecan be designed to allow for a second device, or a suitable fluid (suchas contrast fluid, an oxygenated fluid, or a thrombolytic agent), to bepassed through the tube to a point distal to the distal portion of thecerebral vasculature device.

Shown in FIG. 16 is a representative core wire 12. As can be seen, thecore wire outer diameter is gradually tapered down from a first,relatively larger outer diameter at one end, to a second, relativelysmaller outer diameter, to a third relatively even smaller diameter,etc. Any number of distinct tapered sections can be provided, or arelatively constant taper over the entire length of the wire can beprovided. As shown in FIG. 17, the core wire 12 can be provided with oneor more outer coils 5 and 13 fit over the core wire 12. The outer coils5 and 13 can be used to vary the stiffness of the core wire along itslength, for example. The outer coils can be, for example, metal and canbe soldered (or otherwise attached, e.g., glued, etc.) to the core wire12 at one or more points along the length of the core wire. In an aspectof the invention the coil(s) can be radioopaque metal such as, forexample, platinum, gold, iridium, or platinum/iridium alloy. As shown,coils 5 and 13 overlap each other and are soldered to core wire 12 at19. Moreover, as shown, coil 5 also includes tip 17 soldered (orotherwise attached) to the distal end of core wire 12. In an aspect ofthe invention, coil 5 can be located distal to the distal portion of thebraided structure. Moreover, at least a portion of coil 13 can extendproximally into the distal portion of the braided structure when thedevice is assembled.

It should now be understood that the first expandable portion isexpanded when the physician pulls the proximal end of the core wire in aproximal direction while holding the catheter shaft stationary. Theatraumatic component then applies a proximal force to the distal portionof the device, which results in the first expandable portion radiallyexpanding. The polymer imbedded into the braided structure of theproximal portion and the distal portion serves to radially constrainthese portions, thus preventing them from expanding.

The device can further comprise at least one radioopaque marker band.The marker bands can be any suitable radioopaque material, such as thosedescribed above. In an aspect of the invention, the at least oneradioopaque marker band can lie in a recess provided in the polymermaterial. The at least one radioopaque marker band can be providedproximal and/or distal to the first expandable portion.

In an aspect of the invention, the expandable portion has a length inits unexpanded state of about 1 cm or less. In a further aspect of theinvention, the expandable portion has a length of about 5 mm or less. Ina still further aspect of the invention, the expandable portion has alength of about 4 mm.

As mentioned above, the expandable portion will radially expand when thecore wire is moved in a proximal direction relative to the proximalportion of the device. When expanded, the first expandable portion canhave any suitable diameter. In an aspect of the invention, the maximumexpanded diameter of the first expandable portion is about 6 mm or less.In a further aspect of the invention, the maximum diameter of the firstexpandable portion is about 4 mm or less. In a still further aspect ofthe invention, the maximum diameter of the first expandable portion isabout 3.3 mm.

The device can further include a handle coupled or otherwise attached tothe proximal end of the braided structure, or the proximal end of thecatheter shaft as the case may be. The handle can, in addition toallowing for manipulation of the device through a patient's vasculature,be provided with a mechanism for expanding the expandable portion of thedevice. For example, shown in FIGS. 18, 19, and 20 is a suitable handleconstruction. Shown attached to the distal end of the handle 20 is thedevice shaft or the braided structure proximal portion 2. The handle 20comprises a strain relief section 21 at the distal end of distal housing22. Coupled to distal housing 22 is proximal handle portion 23 whichincludes ribbed section 24. Pin 26 may be provided to fix core wire 12to the proximal housing 27. Proximal housing 27 fits over proximalportion 23. Proximal housing 27 includes cantilever arm 29. Moreover,proximal portion 23 also includes pin or protrusion 25 which is sized tofit into helical slot 30 in proximal housing 27. Finally, handle 20 caninclude safety lock/pin 28 and end cap 31, which is insertable intoproximal housing 27.

To operate the handle 20, safety lock/pin 28 is removed and proximalhousing 27 is rotated relative to proximal portion 23 and distal housing22. Rotation will slowly withdraw core wire 12 and thus cause firstexpandable portion 4 (and when present, second expandable portion 10) toradially expand. The ribbed section 24, along with the cantilever arm 29allows for incremental locking of the core wire as it is retracted.

A method for producing the device according to the present inventionincludes, forming the desired braided structure having a lumen extendingfor the length thereof. The braided structure can then be at leastpartially (and preferably essentially completely) imbedded with asuitable polymer material, for example, by dip coating the braidedstructure into a suitable polymer. Once the polymer is cured, the firstexpandable portion can be obtained by removing the polymer from adesired length of the braided structure near the distal tip of thestructure. Suitable methods for removing the polymer include, forexample, by laser ablation, abrasion (e.g., micro abrasion methods),etc.

After removing the polymer to form the first expandable portion, asuitable atraumatic component can be located at the distal tip of thedevice (i.e., distal to the distal end of the device). The atraumaticcomponent need not be bonded or attached to the distal portion of thedevice. Suitable core wire can then be attached at its distal end to theproximal end of atraumatic component 5 and then inserted through thelumen of the distal section of the device and advanced proximally untilthe proximal end of the core wire extends through the lumen of theproximal section of the device.

The core wire can be any suitable material, such as any suitable metal.The core wire can be tailored to have a varying stiffness over itslength (i.e., relatively stiff at its proximal end to relativelyflexible at its distal end). The core wire may be attached to atraumaticcomponent in any suitable fashion.

Without intending to limit the scope of the present invention, thefollowing example illustrates how a device according to the presentinvention may be made and used.

Nitinol wire can be obtained with a nominal diameter of 0.001 inch from,for example, Fort Wayne Metals (Fort Wayne, Ind.). This wire can bewound on 16 bobbins, where 3 ends of wire are on each bobbin. This wirecan be braided onto a suitable 0.010 inch mandrel (e.g., silver-platedcopper) at 26 PPI (or about 7 degrees as measured from the longitudinalaxis). The wire can then be dip coated with a PEBAX® 7033 resin so thatthe resin fully impregnates the braided structure down to the mandrelsurface. Multiple dipping/heating steps can be applied until an outerdiameter of 0.016 inch is obtained. This tubing can then be cut to 180cm in length. An excimer laser of suitable wavelength can then be usedto fully ablate away the polymer while leaving the wires relatively freefrom damage in a 4 mm section of tubing located 2 mm from the distal endof the tubing. One suitable alternative to laser ablation for removingthe polymer to form the expandable portion includes removing the polymerby abrasion utilizing a suitable abrasive material in a high velocitygas stream. In one exemplary method, sodium bicarbonate with an averageparticle size of 25 microns can be mixed into an airstream at 30-120 psiand directed to a portion of the tubing through a small orifice. Uponimpingement of the surface, the abrasive particles will act to removethe polymer at little or no detriment to the wires. A core wireconsisting of a 2 meter long stainless steel wire of 0.008 inch diametercan be obtained (for example from Precision Wire Components, PWC,Tualatin, Oreg.). The wire can be ground down over its distal 25 cm witha taper to 0.002 inch in diameter. The distal 1 cm can be rolled flatwith a short edge of 0.001 inch. A small coil of 0.0015 inchplatinum/iridium alloy wire can be manufactured with a tapering outerdiameter of 0.010 inch to 0.007 inch and a length of 11 mm. This coilcan be soldered onto the core wire 28 mm from its distal edge. Anothercoil of 0.002 inch platinum/iridium alloy wire can be manufactured to be33 mm in length with an inner diameter of 0.010 inch. This coil can bepositioned over the core wire aligned with the distal tip of the corewire and overlapping the tapered coil by about 5 mm. This can besoldered onto the smaller coil and also to the distal tip of the corewire.

The proximal end of the core wire can be assembled through the innerdiameter of the braided tubing until the tapered coil is pulled into thedistal portion of the device, thus centering the core wire in the lumen.

The device can be used to remove thrombus from very delicate, tortuouscerebral vasculature. One method of using the device includesintroducing the device using well known techniques (for example,percutaneously introducing the device). The device can be advanced to atarget region in the cerebral vasculature through the lumen of knownmicrocatheters. Of course, use of a microcatheter may not be needed ifthe device is designed to have the necessary flexibility and pushabilityto be advanced without a microcatheter. In an aspect of the inventionthe device is advanced to the target region while retrograde blood flowis maintained in the target vessel. In a further aspect of theinvention, the device can be advanced to a point just proximal to thetarget region under antegrade blood flow conditions, and underretrograde blood flow conditions as the distal tip of the device crossesthe thrombus located in the target region. Retrograde blood flow can beobtained by any suitable technique, such as by applying suction to thetarget vessel, or by natural physiological manipulation using themethods and apparatus taught by, for example, Dorros et al. in U.S. Pat.No. 6,929,634, the subject matter of which is herein incorporated byreference. Once the thrombus is crossed by at least the first expandableportion of the device, the expandable portion can be expanded and thethrombus pulled back in a proximal direction, preferably still underretrograde blood flow conditions, to remove the thrombus from thepatient. In some instances of well adhered or large thrombus, it may beparticularly useful to use the expandable portion of the device tomacerate or break apart the thrombus into smaller pieces by cycling theexpansion and collapse of the expandable portion of the device.

While particular embodiments of the present invention have beenillustrated and described herein, the present invention should not belimited to such illustrations and descriptions. It should be apparentthat changes and modifications may be incorporated and embodied as partof the present invention within the scope of the following claims.

1. Cerebral vascular device comprising: continuous braided structurecomprising a plurality of wires, the braided structure having a proximalportion, a distal portion, a first expandable portion between theproximal portion and the distal portion, and a lumen extending from theproximal portion to the distal portion; the proximal portion and thedistal portion each having an outer diameter and an inner diameter andfurther including polymer imbedded at least partially into the braidedstructure; core wire having a proximal end and a distal end, the corewire located within the lumen and extending from the braided structureproximal portion to a point at or distal to the braided structure distalportion; and atraumatic component attached to the core wire distal endand having an outer diameter at least equal to the inner diameter of thebraided structure distal portion.
 2. The cerebral vascular device ofclaim 1, wherein the atraumatic component is selected from the groupconsisting of polymer tubular structures and metal coils.
 3. Thecerebral vascular device of claim 2, wherein the metal coil comprisesradioopaque material.
 4. The cerebral vascular device of claim 3,wherein the radioopaque material comprises a material selected from thegroup consisting of platinum, gold, iridium, and platinum/iridium alloy.5. The cerebral vascular device of claim 1, wherein the braidedstructure proximal portion and distal portion have an outer diameter ofabout 0.020 inch or less.
 6. The device of claim 5, wherein the braidedstructure proximal portion and distal portion have an outer diameter ofabout 0.017 inch or less.
 7. The device of claim 1, wherein theplurality of wires comprise metal wires.
 8. The device of claim 7,wherein the plurality of wires comprise nitinol.
 9. The device of claim1, wherein the polymer comprises a material selected from the groupconsisting of polyimide, peba, polyurethane, nylon, silicone, andpolyethylene.
 10. The device of claim 1, wherein the polymer preventsradial expansion of the braided structure proximal portion and distalportion during expansion of the expandable portion.
 11. The device ofclaim 1, wherein the polymer substantially completely imbeds theproximal portion and the distal portion of the braided structure. 12.The device of claim 1, wherein the braided structure is comprised of aplurality of wires selected from the group consisting of round profilesand flat profiles and combinations thereof.
 13. The device of claim 12,wherein the wires have a round profile.
 14. The device of claim 13,wherein a majority of the wires have an outer diameter of about 0.002inch or less.
 15. The device of claim 14, wherein a majority of thewires have an outer diameter of about 0.0015 inch or less.
 16. Thedevice of claim 15, wherein a majority of the wires have an outerdiameter of about 0.001 inch or less.
 17. The device of claim 1, whereinat least one of the wires comprises radioopaque material.
 18. The deviceof claim 17, wherein the radioopaque material comprises a materialselected from the group consisting of platinum, gold, iridium andplatinum/iridium alloy.
 19. The device of claim 1, further comprising atleast one radioopaque marker band.
 20. The device of claim 19, whereinthe device comprises at least 2 radioopaque marker bands.
 21. The deviceof claim 20, wherein at least one marker band is located distal to theexpandable portion and at least one marker band is located proximal tothe expandable portion.
 22. The device of claim 1, wherein the polymercomprises radioopaque material.
 23. The device of claim 22, wherein theradioopaque material comprises a material selected from the groupconsisting of barium sulfate and bismuth trioxide.
 24. The device ofclaim 19, wherein the at least one radioopaque marker band isessentially flush with the outer diameter of the proximal and distalportions of the device.
 25. The device of claim 1, wherein the device isattached to the distal end of a tubular structure.
 26. The device ofclaim 25, wherein the tubular structure is a continuation of theproximal portion of the braided structure.
 27. The device of claim 25,wherein the tubular structure has an outer diameter of about 0.020 inchor less.
 28. The device of claim 1, wherein the expandable portion has alength in its unexpanded state of about 1 cm or less.
 29. The device ofclaim 28, wherein the expandable portion has a length of about 5 mm orless.
 30. The device of claim 29, wherein the expandable portion has alength of about 4 mm.
 31. The device of claim 12, wherein the pluralityof wires numbers 48 wires or more.
 32. The device of claim 12, whereinthe plurality of wires numbers 32 wires or more.
 33. The device of claim12, wherein the plurality of wires numbers 16 wires or more.
 34. Thedevice of claim 1, wherein the braided structure comprises wiresoriented at an angle of about less than or equal to 10 degrees asmeasured from the longitudinal axis of the braided structure.
 35. Thedevice of claim 34, wherein the braided structure comprises wiresoriented at an angle of about less than or equal to 8 degrees asmeasured from the longitudinal axis of the braided structure.
 36. Thedevice of claim 1, wherein the expandable portion has a diameter in itsmaximum expanded state of about 6 mm or less.
 37. The device of claim36, wherein the expandable portion has a diameter in its maximumexpanded state of about 4 mm or less.
 38. The device of claim 37,wherein the expandable portion has a diameter in its maximum expandedstate of about 3.3 mm.
 39. The device of claim 25, wherein the core wireextends for at least the length of the tubular structure.
 40. The deviceof claim 39, wherein the combination of the core wire and the tubularstructure has a change in flexibility from a proximal point to a distalpoint thereon.
 41. The device of claim 40, wherein the distal point ofthe tubular structure is more flexible than the proximal point of thetubular structure.
 42. The device of claim 39, wherein a handle iscoupled to the core wire and the tubular structure, the handle providingfor actuation of the expandable portion.
 43. The device of claim 1,wherein the expandable portion is atraumatic to a patient's vessel whenin its maximum expanded state.
 44. The device of claim 43, wherein theexpandable portion is suitable for removing a clot from the patient'svessel.
 45. The device of claim 1, wherein the expandable portion has amaximum expanded diameter being equal to or larger than the diameter ofthe patient's target vessel.
 46. The device of claim 1, wherein thebraided structure further comprises a second expandable portion.
 47. Thedevice of claim 46, wherein the braided structure further comprises anintermediate portion located between the first expandable portion andthe second expandable portion.
 48. The device of claim 47, wherein theintermediate portion comprises polymer imbedded at least partially intothe braided structure.
 49. The device of claim 47, wherein theintermediate portion is radially constrained by a polymer covering. 50.The device of claim 47, wherein the intermediate portion is radiallyconstrained by a metal band.
 51. The device of claim 47, wherein theintermediate portion is of a higher braid angle than the expandableportions.
 52. The device of claim 25, wherein the device and tubularmember are sized to be suitable for delivery through a microcatheter.53. The device of claim 52, wherein the device and tubular member do notimpose bending force to a straight microcatheter.
 54. The device ofclaim 1, wherein the first expandable portion comprises a plurality ofwires oriented at a first angle and at least a portion of the braidedstructure comprises wires oriented at a second angle different from thefirst angle.
 55. The device of claim 1, wherein the device is removablyattached to a distal end of a catheter shaft.
 56. The device of claim 1,wherein the expandable portion is provided with an outer polymer cover.57. The device of claim 56, wherein the outer polymer cover comprisesePTFE.
 58. Method for making a cerebral vascular device comprising thesteps of: providing a continuous braided structure having a length, alumen extending therethrough, and having polymer at least partiallyimbedded therein for substantially the entire length of the braidedstructure; removing at least a portion of the polymer from the braidedstructure to form an expandable portion, a proximal portion havingpolymer at least partially imbedded therein and a distal portion havingpolymer at least partially imbedded therein, the expandable portionbeing located between the proximal portion and the distal portion;attaching an atraumatic component to a core wire, the core wire having aproximal end and a distal end; locating the core wire within the lumen,the core wire extending from the braided structure proximal portion to apoint distal to the braided structure distal portion; and wherein theatraumatic component has an outer diameter at least equal to the innerdiameter of the braided structure distal portion.
 59. The method ofclaim 58, wherein the polymer is provided by a dip-coating process. 60.The method of claim 58, wherein the polymer is removed by laserablation.
 61. The method of claim 58, wherein the polymer is removed byan abrasion process.
 62. The method of claim 61, wherein the abrasionprocess comprises using sodium bicarbonate.